An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack
Abstract
:1. Introduction
2. Experimental Setup
3. Results and Discussion
3.1. Effect of Tool Wear on the Thrust Force
3.2. Effect of Tool Wear on the Cutting Temperature
3.3. Tool Wear Mechanism and Progression
3.4. Effect of Tool Wear on Drilled Hole Quality
3.4.1. CFRP Entry Delamination
3.4.2. CFRP Exit Delamination
3.4.3. Hole Size Accuracy
4. Conclusions
- As the drilled hole number increased, the cutting torque and thrust increased for both machining techniques. However, VAD resulted in up to 25% and 45% reduction in the thrust force and cutting torque, respectively.
- For N = 56.52 m/min cutting speed and 0.075 feed, increasing the modulation amplitude hindered the tool-chip welding.
- LF-VAD showed a significant reduction in the machining thermal load. The exit cutting temperature was reduced by 40%, compared to the CD.
- Up to 75% reduction on the flank wear-land was achieved by VAD with high modulation amplitude. Moreover, the tool surface profile examination showed a low cutting edge roundness (CER) compared to the conventional machining process.
- Vibration-assisted drilling showed an acceptable entry and exit delamination for all the investigated machining parameters.
- The effect of tool wear progress was significant for CD at low cutting speed, while the high thermal load and poor evacuation efficiency resulted in un-acceptable delamination at the high cutting speed.
- A significant enhancement of the CFRP and Ti6Al4V geometrical accuracy has been achieved by VAD, compared to CD.
Author Contributions
Funding
Conflicts of Interest
Acronyms
VAD | Vibration-assisted drilling |
LF-VAD | Low frequency-vibration-assisted drilling |
CD | Conventional drilling |
HSS | High-speed steel |
BUE | Built-up edge |
A | Initial wear region |
B | Steady wear region |
C | Severe wear region |
CER | Cutting edge radius |
VB | Average flank wear-land |
Notations
N | Cutting speed [m/min] |
f | Feed rate [mm/rev] |
Am | Modulation amplitude [mm] |
F | Frequency [Hz] |
Ød | Delamination factor [%] |
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Elements by Elements by Weight % | |||||||
---|---|---|---|---|---|---|---|
C | O | Al | Ti | V | W | Total | |
Spectrum 1 | 45.66 | 28.89 | 1.29 | 21.8 | 0.99 | 1.09 | 100.0 |
Spectrum 2 | 13.68 | 26.77 | 4.32 | 50.22 | 1.68 | 3.01 | 100.0 |
Spectrum 3 | 8.91 | 42.9 | 3.6 | 43.07 | 1.5 | 0.1 | 100.0 |
Spectrum 4 | 7.42 | 40.29 | 3.57 | 47.02 | 1.53 | 0.19 | 100.0 |
Spectrum 5 | 10.64 | 44.7 | 4 | 38.47 | 1.59 | 0.59 | 100.0 |
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Hussein, R.; Sadek, A.; Elbestawi, M.A.; Attia, M.H. An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack. J. Manuf. Mater. Process. 2019, 3, 63. https://doi.org/10.3390/jmmp3030063
Hussein R, Sadek A, Elbestawi MA, Attia MH. An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack. Journal of Manufacturing and Materials Processing. 2019; 3(3):63. https://doi.org/10.3390/jmmp3030063
Chicago/Turabian StyleHussein, Ramy, Ahmad Sadek, Mohamed A. Elbestawi, and M. Helmi Attia. 2019. "An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack" Journal of Manufacturing and Materials Processing 3, no. 3: 63. https://doi.org/10.3390/jmmp3030063